Transfer Shaft Repair

TRANSFER SYSTEM-TRANSFER SHAFT/GEAR/BEARING
REMOVAL





1. Remove transfer gear cover bolts (Fig. 265).





2. Separate transfer gear cover from transaxle (Fig. 266). Repair any cover imperfections. Clean cover and case of old adhesive sealant.
3. Using a suitable punch, bend retaining strap tabs to facilitate bolt removal.
4. Remove stirrup and retaining strap-to-transfer gear bolts.
5. Remove stirrup and retaining strap.








6. Using Tool L-4434(Fig. 267), remove transfer shaft gear retaining nut and washer (Fig. 268).





7. Using Tool L-4407A, remove transfer shaft gear and select shim (Fig. 269).





8. Using Tool L-4406-1 and adapter L-4406-3, remove transfer shaft gear bearing cone (Fig. 270).





9. Remove governor support retainer (Fig. 271).





10. Remove governor support retainer bearing cup (Fig. 272).





11. If necessary, remove low/reverse band anchor pin (Fig. 273).





12. Remove governor assembly (Fig. 274).





13. Remove transfer shaft bearing retainer snap ring (Fig. 275).





14. Set up tools as shown in (Fig. 276).





15. Remove transfer shaft/bearing retainer assembly (Fig. 277).





16. Separate bearing retainer from transfer shaft (Fig. 278).





17. Remove transfer shaft bearing cone from shaft using Tool C-293-PA and adapters C-293-52 (Fig. 279).





18. Remove transfer shaft bearing cup from bearing retainer (Fig. 280).

INSTALLATION





1. Install transfer shaft bearing cup to bearing retainer using Tool L-4520 (Fig. 281).





2. Install transfer shaft bearing cone to transfer shaft using Tool L-4111 (Fig. 282).





3. Assemble transfer shaft to bearing retainer (Fig. 283).





4. Install transfer shaft/bearing retainer assembly using tool L-4512 (Fig. 284).





5. Install transfer shaft bearing retainer snap ring (Fig. 285).





6. Install governor assembly (Fig. 286).





7. Install low/reverse band anchor pin if previously removed (Fig. 287).





8. Install governor support retainer bearing cup using Hoot L-4520 (Fig. 288).





9. Install governor support retainer (Fig. 289).





10. Install transfer shaft gear bearing cone using Tool L-4410 (Fig. 290).
11. Determine transfer shaft bearing shim thickness. Shim thickness need be determined only if any of the following parts are replaced:
- Transaxle case
- Transfer shaft
- Transfer shaft gear
- Transfer shaft bearings
- Governor support retainer
- Transfer shaft bearing retainer
- Retainer snap ring
- Governor support





12. Install transfer shaft gear and select shim (Fig. 291).





13. Install transfer shaft gear nut and washer (Fig. 292).





14. Using Tool L-4434 and adapter C-4668 (Fig. 293), torque transfer shaft gear retaining nut to 271 Nm (200 ft. lbs.).





15. Measure transfer shaft end play. Set up Tool L-4432 and C-4658 as shown in (Fig. 294). Measure end play with dial indicator.
16. Position stirrup and strap on transfer gear.
17. Install bolts but do not tighten.
18. Rotate stirrup clockwise until it contacts transfer gear retaining nut flat.
19. Torque stirrup and strap-to-transfer gear bolts to 23 Nm (200 inch lbs.).
20. Bend tabs of strap up against "flats" of retaining bolts.





21. Install a bead of Mopar Silicone Rubber Adhesive Sealant to transfer gear cover (Fig. 295). Immediately install to transaxle case.





22. Install and torque transfer gear cover-to-case bolts (Fig. 296) to 19 Nm (165 inch lbs.).